Film shaping and laminating device



Aug. l, 1944. A, M MAKS 2,354,692

FILM SHAPING AND LAMINATING DEVICE .7. ".'qr" .0417" "I, d: A) 1427! ffy/yar# E@ .540 LU/ ,652 zur aa T259 INVENTOR alain Qn. WKO/w42@ Y] f '2 A K ATTORNEY Aug 1, 1944. M. MARKS 2,354,692

ILMSHAPING AND LAMINATING DEVICE Filed J'an. 21, 1941 2 Sheets-Sheet 2 IZ 14a Y B )a2/:mon

ATTORNEY.

vpressure and heat.

Patented Aug. l, 1944 UNITED STATES PATENT GFFICE I FILM snAPmG AND LAnnNA'rrNG DEVICE Alvin M. Marks, Whitestone, Long Island,` N. Y. application January 21, 1941, serial No. A:475,151

1o claims; (cl. 1544-1) 4 My invention relates to a toric expander and more particularly my invention relates to a novel apparatus and method for expanding and shaping a plastic film containing a crystalline layer. This application is a continuation in part of my copending application Serial No. 313,392, for Polarizing crystalline formation by transfer and expansion, filed January 11, 1940, in which I have disclosed a method for forming a crystalline layer on a plastic lm, and an apparatus and method for expanding the same. For certain purposes such as, for example, in the formation of polarized toric lenses, it is necessary that the plastic iilm carrying the polarizing crystalline layer be shaped to a toric shape and laminated between two toric lenses. This shaping,expand ing and lamination I prefer to carry out under special conditions including vacuum, tension,

I have devised a novel apparatus by means of which I may thus expand and shape a plastic film carrying a crystalline layer and by means of this apparatus I may employ the toric lens to which the plastic film is to be laminated as the shaping means.

I further provide means for uniformly and with equally exerted Atension and pressure simultaneously expand and shape the plastic film carrying a crystalline layer over said toric lens. I also provide for laminating a second torio lens over the plastic lm which has been shaped and expanded about the first toric lens.

A further feature of my invention lies in certain means which I provide for controllingthe movement of my expansion apparatus to certain predetermined limits.

It is the object of my invention to provide a. novel' expanding and laminating apparatus and method.

It is a further object of' my invention to provide a novel expander for imparting a torio shape to the plastic medium. A l,

It is a further object of my invention to provide a novel toric expander for a plastic film carrying al crystalline layer or eld.

It is a further object of my invention to provide a novel apparatus by means of which the plastic lm is drawn down over a shaping medium which shaping medium forms a portion of the nished product of my invention.

It is a further object of my invention to prober carrying a plastic iilm is caused to move down- Wardly over a shaping medium so that the plastic film carried by the ring is expanded and shaped by the shaping medium.

It is a further object of my invention to provide an expander apparatus in which the vertical movement of the travelling gripping ring is gov erned by predetermined sensitive snap switches.

Further objects of my invention will be appar- -ent from a consideration of the drawings and the specific description thereof which here follows:

In Figure l I show a side view and partial cross section of the torio expander of my invention.

In Figure 2 I show a plan view of the apparatus of my invention with the vacuum hood removed therefrom.

' Figure 3 is a side view of the apparatus of my invention taken in a plane normal to the view of Figure 1.

Figure 4 is a diagrammatic layout of the reversing electrical circuit. p

Referring now more specihcally to the drawings, in Figure 1 I show rising from a suitable support II), posts II and I2 which act as the sup' porting frame for my apparatus. Supporting posts II and I2 are secured to the support III by means of suitable nuts I3 and I 4. Y

A pulley -Iii locked on to a-shaft I1 -by the pin I8 is adapted to be rotated by a pulley and suitable motor source of power not shown. Shaft I1 is mounted in supporting posts 20 and 2I' (see Figure'2) which are aixed to an upper frame plate 22 by suitable securing means 23 and 24. Affixed on the shaft I1 are worms 26 and 21 (see alsoFigure 3) which are adapted to engage worm gears 30 and 3I pinned to shafts 32 and 33 by pins 34 and 35. The shafts 32 and 33 are verticallyA the screw thread bearings 48 and 43 and lockvide a novel means for expanding and shaping a plastic film over a torio lens in combination with means for laminating a second toriclens over the expanded and shaped plastic film.

ing-nuts 50 and 5I is vlimiting plate 52 which moves upwardly or downwardly depending upon the direction of rotation of the screw thread areas 46 and 41 `of the shaft 32 and 33.

` Upon upwardmovement of the upper limiting plate contact is effected by the limiting plate with ni pin sa of the sensitive snap switch sa. Upon downward movement of the limiting plate '52 contact is effected between stud 56 mounted on thevlimiting plate 52-and the wedge member 51 which in turn contacts the pin 58 of the sen- The upper portions of the shafts 32 and 33 also i have screw thread areas 65 and 66 and in screw thread engagement with these screw thread areas 65 and 661s a ring 61 having threaded openings. Into the ring 61 is set and secured asplit ring 68 adapted to carry a plastic lm 69 which carries a crystalline layer, such as of polarizing crystal. The ring 68 is a split ring comprising two parts, namely an upper part 10 and a lower part 1|. Inasmuch as the operating chamber 13 is to be evacuated, the'intermediate length of the shafts 32 and'33 pass through packing chambers 16 and 11 and the packings may be adjusted by the packing glands 18 and 19. A shaping member, such as a toric lens 60, is set on a seat 8| and ring 82 fits around the outer edge of the seat 8| to hold the iensil in place. Seat 8| is hollow and is secured to block 84 by suitable securing bolts 85and 86. The block 84 is also hollow being provided with a heating chamber 88 into which is fed a heating fluid such as hot water. or steam through a supply pipe 89, a similar pipe 90 being provided as shown in Figure 2 for withdrawing the heated uid from the chamber to provide circulation thereof. A vacuum pipe 82 enters the chamber 13 as shown in dotted line and the vacuum pipe is connected with a suitable means for evacuation such as a vacuum pump 2li shown diagrammatically in Figure 4. To provide a hermetically sealed Vac-- uum chamber, -a vacuum hood comprising an upper plate 94, a lower ring-plate 85 secured together by bolts, such al 96, and' a transparent cylindrical wall 91, is seated on the gasket 98 which is set in a suitable gasket receiving seat formed in the block 84.

A plunger having impelling head 0| and operating head |02 is slidably mounted in the bearing |03 and resiliently held in a normally retracted position by the spring |04. A packing chamber |06 which may be adjusted by the packsliding. plunger |00. Aillxed to the operating head |02 are spring members |09 and ||0 which are adapted to hold a, lens against a pressure head ||2 which is fixed to the operating head |02.

By referring to Figure 2 the operation of the vertically-moving ring 61 becomes more clearly apparent. Ring 61 carries equi-laterally mounted thereon pins |20, |2| and |22 which carry pivoted retaining plates |24, |25 and |26. These plates are adapted tol engage the split ring 68 which carries the plastic lm firmly mounted therein. Also shown lhere is the micrometer |30 and indicator 3| which permit adjustment of the limit laterally by the rotation of the micrometer |30.

For guiding its movement riding mem-ber |36 is mounted on a rod I 31 which is supported by and may slide through holes in the plate |34 and the support |35. Aillxed to the bottom'of the riding member |36 is a spring extension |40 which carries at its extremity a wedge-member |4|. The wedge member |4| has the, function of lessening the path of downward movement of the limiting plate 52 since the pressure thereupon by the stud 56 fixed on the plate 52 causes the wedge member to engage the pin 58 of the snap `switch 55|. Retraction of the wedge, as will be more clearly apparent from a, detailed description hereinafter, lengthens the path of downward travel of the limiting plate 52. To provide for an adjustment of the upward path of the limiting plate |52 with regard to the limiting snap switch `'54, -I secure an extension member 55 to the limiting plate 52, the extension member being provided with a contact |50 for exerting pressure on the sensitive snap switch pin 53. Contact |50 is adjustable with regard `to its height by the adjusting screw |5|.

The operation of my apparatus is as follows: vA torio lens 80 is set in the seat member 8| and retained in position by the retaining ring member 82. Thislens may, for example, be a toric lens adapted to be a component element of a torio laminated lens for spectacles. Alternatively 80 may represent any suitable shaping member adapted to impart the desired shape to a moldable iilm which may carry a crystalline layer. A

kplastic film 69 carrying a crystalline layer formed, for example, as described in my co-pending application Serial No. 313,392 is secured be-4 tween the two elements 'l0 and 1| of the split ring 68. The two elements 10 and 1| are 'se-l cured together as shown in Figure 2 by securing means |23. The split ring carrying the tautly held plastic film 69 is then set `in the ring member 61 and the pivoted retaining plates |24, 4|25 and |26 are swung into position so as to lock the ring 68 rmly in position. If a laminated e toric lens is to be made a lens I is mounted ing gland |01 assures an air tight seal for the of the downward movement of limiting plate 52 eter |30 is mounted on a screw threaded rod shaft |32 and is adapted to be rotated by the operator of the apparatus. mounted in the plate |34 and is mounted in a The shaft |32 is rotatably threaded'hole in the support |35. In xed ro- 75 on the operating head |02 of theplunger |00 by the spring retaining members |09 and ||0. I'he vacuum hood 94 is then placed in position on the gasket 98 so that an air tight seal is obtained therewith. The operating chamber 13 is evac-l of the vertical rods 32 and 33 to which thes'ej worm gears are aiiixed. 'I'he rotation of the vertical rods 32 and 33, if the rotationisin a right hand direction, causes the lowering of'both thej limiting plate 52 and the rin'g 61 which are'" mounted in screw thread engagementfwith the." i

screw thread areas of these rods. Retaining ring 61 carrying with it the 80. 'I'he equally distributed pressure exerted upon the plastic film 69 causes thefilmlandthe crystalline layer thereon tov be expanded and shaped over the lens 80. In the meantime the .pli ne N ss in which is fixed the plastic fum' satiierifingves downwardly and is drawn over the shaping lens" limiting plate 52 has moved down a corresponding distance and at the proper predetermined point the stud 56 on the underside of the limiting plate 52 contacts the wedge |4'I causing the wedge I4I in turn to press against pin 58 of the sensitive snap switch 59.

l The actuation of the snap switch 59 stops the power source which rotates the pulley I6. The

reversal of the motor is effected by the operator after lamination of the upper lens by reversing the switch to position I |1 (Figure 4), whereupon the limiting plate 52 and the ring 61 move upwardly to return to original position. When the original predetermined position is reached the limiting plate 52 presses ,against the pin 53 of the snap switch 54 to cause the motor to stop. The apparatus is then ready for opening and reuse.

In Figure 4 I show the basic circuit by means of which I control the various operations of my apparatus. A reversible motor 200 is energized in such a manner as to cause the worms 26 and 21 to effect such rotation of screws 65 and 66 to cause causes the upward motion of the ring 61 together with the laminated lens bonded to the film 60 held by the ring 61, the upward motion lbeing'now limited by sensitive snap switch 54 through which the current supplying the motor 200 must .travel to reach the line L 2.

Simultaneously with the reversal of the knife switch, vacuum pump motor 2|0 and air valve 2I| are de-energized thus stopping the vacuum pump 2l I and opening the vent Vto the atmosphere through air valve-2I2 and air lter 2|3, thus equalizing the pressure in chamber 13 with the atmospheric pressure.

When the the ring 61 has reached the proper point in its path of upward travel, the limiting y plate 52 contacts the pin 53 and sensitive snap the downward movement of the film 69 in the ring 61 by contacting the blades 215, 2I6 and 2|1, re-

switch 54, which in turn shuts ci the current to the motor, stopping the motor and stopping the movement of the ring `6'I Since the pressure in the operating chamber 13 has been equalized, the. vacuum hood 94 may now be removed from con tact with the gasket 90 and the inner ring 601s then disengaged from the outer ring 61 by pivoting the holder plates |24, |25 and |26. The split ring 68 is then disassembled and theexcess plastic trimmed away from the periphery of kthe lamination.

Lenses 80 and III may be coated, if desired, on their 'inner contacting surfaces in some suitable manner with appropriate adhesive compounds before being placed in their positionfor the lamitive snap switch 59 successively via a path through Y contacts 205, 2I1, 2|6 and 204. Accordingly, the

' opening of snap switch 59 opens the circuit stopping the motor 200 and thus limiting the downward motion of the ring 61.

Upon completion of the necessary downward Y motion to effect the expansion and lamination of the lm 69 withthe lens 00, the operator next manually, or by a suitable mechanism, lpresses down upon the pressure pad I0 I, thus causing lens II to laminate itself to the upper surface of the expanded plastic lm 69. Plastic film 69 which may 'for example comprise'cellulose derivatives such as cellulose acetate or any suitable plastic plunger is released, spring fingers |00, and |I0 disengaging from the cover lens I I which remains rmly bonded and in contact with the plastic film 00, the holder |02 being retracted to its original position by the spring |04. When the lamination operation has been thus completedthe operator reverses the knife blades 2|4, 2I5 and2|6 and 2| 1 to make contact with the contacts 206, 201, 200 and 209. This causes motor 200 to reverse inasmuch as the current through coil 220 reverses direction while current through coil 22| continues in the same direction. 'I'he reversal of the motor retaining ring to movedown over'said toric shaping member.

2. A shaping apparatus comprising in combination means for holding a film to be shaped, said means comprising a ring,. means for removably (gripping lsaid ring, said means comprising a retaining ring, said retaining ring being mounted on screw threaded rods, a toric shaping member, means forrotating said rods to cause said retaining ring to move down over said toric shaping member, and means for reversing the movement of said screw threaded rods to cause ygripping said ring', said means comprising a rethe retaining ring to move upwardly.

3. A shaping apparatus comprising in combination means for holding a lm to be shaped, said means comprising a ring, means for removably taining ring, said retaining ring being mounted onscrew threaded rods, a shaping member, means for rotating said rods to cause said retaining ring to move down over said shaping member, means for reversing the movement of said screw threaded rods to cause the retaining ring to move upwardly, and means for limiting the movement of said retaining ring.

4. A'shaping apparatus comprising in combi-` nation means for holding a lm to be shaped. said means comprising a ring, means for re- Nmovably gripping said ring, said means vcomprising a retaining ring, said retaining ring being mounted on screw threaded rods, a toric shaping member, means for heating said shaping member, means for rotating said rods to cause said retaining ring to move down over said toric shaping member so that said nim is drawn tightly ove'r said shaping member, and means for laminating an element over said lm, said means for laminating being positioned so that the lamination is effected while the nlm is drawn tightly over said shaping member.

5. A shaping apparatus comprising in combination means for holding a nlm to be shaped, said means comprising a ring, means for removably gripping said ring, said means comprisingY a retaining ring, said retaining ring being mounted on screw threaded rods, a shaping member, means for heating said shaping member, means for rotating said rods to cause said retaining ring to move down over said shaping vmember so that said nlm is drawn tightly over said shaping member, and means for laminating an elementover said nlm, said means comprising a retractable plunger having a member for releasably holding said element, said means for laminating being positioned so that the lamination is effected while the nlm is drawn'ti'ghtly over said yshaping member.

6. Ay shaping apparatus comprising in combination means for holding a nlm tobe shaped, said means comprising a ring, means `for removably gripping 'said ring, said means comprising a retaining ring, said retaining ring being mounted on screw threaded rods, a\ shaping' member, means for heating said shaping member, means for rotating said rods to cause said retaining ring to move down over said shaping member so that said nlm is drawn tightly over said shaping member, means for laminating an element over said nlm, said means for laminating being positioned so that the lamination is effected while the film is drawn tightly over said shaping member, and means for establishing an evacuated operating chamber over said ring and said shapingmember.

7. A shaping apparatus comprising in combination means for holding a nlm to be shaped and a toric shaping member, means i'or establishing reduced pressure conditions over said means for holding the nlm to be shaped and said toric shaping member, means for bringing said nlm into pressure contact with said toric shaping member, means for heating said toric shaping member, and means for laminating an element to said nlm.

8. A shaping apparatus' comprising in combination means for holding -a nlm to beshaped and a toric shaping member, said toric shaping member comprising a first element adapted to be laminated to said film, means for establishing reduced pressure conditions over said means for holding the nlm to be shaped and said toric shaping member, means for bringing said nlm into pressure contact with said toric shaping member, means for heating said toric shaping member, and means for laminating a second element to said nlm.

9. A shaping apparatus comprising in combination means for holding a nlm to be shaped, said means comprising a split ring adapted to nrmly grip said nlm, means for removably gripping said split ring, said means comprising a retaining ring, said retaining ring being mounted on screw threaded rods and being adapted to 4be moved upwardly or downwardly by the proper rotation of said screw threaded rods, means for rotating said rods, a shapingmember, a seat for positioning said shaping member, means for grippingan element adapted to be contacted with said nlm, means for pressing said element into contact with said nlm after said nlm has been drawn and shaped over said shaping member and while said nlm is still in drawn condition, and means for establishing reduced pressure conditions in said apparatus.

10. A shaping apparatus comprising in combination means for holding a nlm to be shaped, said means' comprising a split ring adapted to nrmly grip said nlm, means for removably gripping said split ring, said means comprising a retaining ring, said retaining ring being mounted on screw threaded rods and being adapted to be moved upwardly or downwardly by the proper rotation oi said screw threaded rods, means for drawn and shaped over said shaping member and while said nlm is still in drawn condition, 'means for establishing reduced pressure conditions in said apparatus, and means for limiting the upward movement of said retaining ring and means for limiting the downward movement oi' said retaining ring.

ALVIN M. MARKS. 

